Powered surgical instrument

ABSTRACT

A powered surgical apparatus, which is configured to engage tissue includes a handle assembly having proximal and distal portions, a movable portion operatively connected to the distal portion of the handle assembly, a tool assembly operatively coupled to the movable portion, a power source configured to supply electrical power, and a transmission system operatively associated with the power source. The movable portion is movable with respect to the handle assembly. The tool assembly is adapted to engage tissue. The transmission system is configured to transmit electrical power or signals between the handle assembly and the movable portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No.14/206,308, filed Mar. 12, 2014, now U.S. Pat. No. 9,364,226, which is acontinuation of U.S. patent application Ser. No. 12/689,386, filed onJan. 19, 2010, now U.S. Pat. No. 8,708,211, which claims the benefit ofand priority to U.S. Provisional Application Ser. No. 61/152,051, filedon Feb. 12, 2009, the entire content of each of which is incorporatedherein by reference.

TECHNICAL FIELD

The present disclosure relates generally to surgical instruments and,more specifically, to powered surgical instruments for engaging tissue.

BACKGROUND OF RELATED ART

Surgical instruments are well known in the art. Certain surgicalinstruments are used for applying parallel rows of staples throughcompressed living tissue. These surgical instruments are commonlyemployed for closing tissue or organs prior to transaction or resection,for occluding organs in thoracic and abdominal procedures, and forfastening tissue in anastomoses.

Typically, such surgical instruments include an anvil assembly, acartridge assembly for supporting an array of surgical staples, anapproximation mechanism for approximating the anvil and cartridgeassemblies, and a firing mechanism for ejecting the surgical staplesfrom the cartridge assembly. In some surgical instruments, the anvil andcartridge assemblies can jointly articulate or rotate with respect tothe rest of the surgical instrument.

In use, a surgeon initially clamps tissue by approximating the anvil andcartridge members to each other. Next, the surgeon fires the instrumentto place staples in the tissue clamped between the anvil and cartridgemembers. Optionally, the surgeon may use the same instrument or aseparate instrument to cut the stapled tissue adjacent or between therow(s) of staples. Alternatively, the surgical instrument cansequentially eject the staples, while the anvil approximates thecartridge.

SUMMARY

The present disclosure relates to a powered surgical apparatus forengaging tissue. This powered surgical apparatus includes a handleassembly having proximal and distal portions, a movable portionoperatively connected to the distal portion of the handle assembly, atool assembly operatively coupled to the movable portion, a power sourceconfigured to supply electrical power, and a transmission systemoperatively associated with the power source. The movable portion ismovable with respect to the handle assembly. The tool assembly isadapted to engage tissue. The transmission system is configured totransmit electrical power or signals between the handle assembly and themovable portion.

BRIEF DESCRIPTION OF FIGURES

Various embodiments of the presently disclosed surgical instrument aredisclosed herein with reference to the drawings, wherein:

FIG. 1 is a perspective view of an embodiment of the surgical instrumentof the present disclosure;

FIG. 2 is a side cross-sectional view of the surgical instrument of FIG.1, showing the internal components thereof;

FIG. 3 is a side cross-sectional view of a movable portion of thesurgical instrument of FIG. 1, showing the internal components thereof;

FIG. 4 is a perspective cut-away view of a portion of the surgicalinstrument of FIG. 1, showing the internal components of the movableportion;

FIG. 5 is a perspective cut-away view of the movable portion and anelongate portion of the surgical instrument of FIG. 1, showing theinternal components of the movable portion; and

FIG. 6 is a perspective top cut-away view of the movable portion of thesurgical instrument of FIG. 1, showing the internal components of themovable portion.

DETAILED DESCRIPTION

Embodiments of the presently disclosed powered surgical instrument aredescribed in detail with reference to the drawings, wherein likereference numerals designate similar or identical elements in each ofthe several views. In the drawings and the description that follows, theterm “proximal” refers to the end of the surgical instrument that iscloser to the operator, whereas the term “distal” refers to the end ofthe surgical instrument that is farther from the operator. Asappreciated by one skilled in the art, the depicted surgical instrumentfires staples, but it may be adapted to fire any other suitable fastenersuch as clips and two-part fasteners. Additionally, the disclosedsurgical instrument may include electrosurgical forceps or graspers.Commonly-owned patent application Ser. No. 10/369,894, filed on Feb. 20,2003 (U.S. Patent Publication No. 2003/0229344), entitled VESSEL SEALERAND DIVIDER AND METHOD OF MANUFACTURING THE SAME, the entire contents ofwhich are incorporated by reference herein, describes in detail a kindelectrosurgical forceps.

With reference to FIG. 1, reference numeral 100 designates an embodimentof the presently disclosed surgical instrument. In the interest ofbrevity, the present disclosure focuses on a transmission system ofsurgical instrument 100. U.S. Patent Publication (USPP) Nos.2008/0105730, filed on Nov. 28, 2007; USPPN 2008/0110960, filed on Jan.8, 2008; USPPN 2008/0142565, filed on Jan. 24, 2008; USPPN 2008/0041916,filed on Oct. 15, 2007; U.S. Provisional Patent Application Ser. No.61/050,273, filed on May 5, 2008; and U.S. patent application Ser. No.11/786,198, filed on Apr. 10, 2007; Ser. No. 11/724,733, filed on Mar.15, 2007; and U.S. patent application Ser. No. 11/786,933, filed on Apr.13, 2007, describe in detail the structure and operation of surgicalinstruments that may incorporate the presently disclosed transmissionsystem. The entire contents of these prior applications are incorporatedherein by reference.

Surgical instrument 100 is configured to clamp, fasten, and/or cuttissue. Generally, surgical instrument 100 includes a handle assembly110, a movable portion 120 adapted to move relative to handle assembly110, an elongate portion 130 extending distally from movable portion 120and defining a longitudinal axis “A-A,” and a loading unit or toolassembly 140 adapted to engage tissue. Tool assembly 140 may include avarious kinds of end effectors 144. Handle assembly 110 has proximal anddistal portions 112, 114. Movable portion 120 extends distally fromdistal portion 114 of handle assembly 110 and is configured to rotatewith respect to longitudinal axis A-A. Since movable portion 120 isoperatively attached to elongate portion 130, rotating movable rotatingportion 120 causes a corresponding rotation of elongate portion 130.Elongate portion 130 has proximal and distal ends 132, 134 andoperatively interconnects handle assembly 110 and tool assembly 140.Tool assembly 140 includes a connecting section 142 releasably mountedonto distal end 134 of elongate portion 130 and an end effector 144.

End effector 144 may be adapted to clamp, fasten, cut, ablate, and/orcauterize tissue. In one embodiment, end effector is reusable.Alternatively, end effector 144 may be part of a disposable loadingunit. U.S. Pat. No. 5,752,644, the entire contents of which are herebyincorporated by reference, describes in detail a disposable loading unitthat can be incorporated to surgical instrument 100. In one embodiment,end effector 144 articulates with respect to longitudinal axis A-A uponmovement of articulation knob 122 or actuation of an articulation switch116 positioned on handle assembly 110.

With reference to FIG. 2, handle assembly 110 includes a handle 111 anda housing 118. Handle 111 defines a longitudinal axis B-B and includes aswitching mechanism 113 disposed thereon. Longitudinal axis B-B issubstantially perpendicular to longitudinal axis A-A. As seen in FIG. 2,switching mechanism 113 may be a rocker switch having two switches 113a, 113 b. Irrespective of its configuration, switching mechanism 113starts and/or stops a first motor 115 when a user presses switch 113 aor switch 113 b. In one embodiment, switching mechanism 113 opens andcloses an electrical circuit connecting a power source 119 to firstmotor 115. In another embodiment, first motor 115 starts and stops whenthe user presses switch 113 a and second motor 126 (see FIG. 3) startsand stops when the user presses switch 113 b. In this embodiment, thetransmission system disclosed in detail below transmits signals orelectrical power from power source 119 to second motor 126.

With continued reference to FIG. 2, housing 118 encompasses power source119, first motor 115, and a drive tube 117. Power source 119 iselectrically connected to first motor 115. In use, power source 119supplies electrical power to first motor 115 when a user presses switch113 a or switch 113 b. In the embodiment depicted in FIG. 2, powersource 119 includes battery cells. Power source 119, however, mayconstitute any device, apparatus, or means capable of supplyingelectrical power. For example, power source 119 may include a batterypack, fuel cells, high-energy capacitors, or any combination thereof. Inone embodiment, capacitors electrically connected to a battery pack formpower source 119. Alternatively, surgical instrument 100 includes a cordconnectable to an electrical energy generator.

Regardless of the kind of power source 119 employed, first motor 115converts the electrical energy received from power source 119 intomechanical motion. First motor 115 is operatively associated with drivetube 117. During operation, drive motor 115 causes drive tube 117 torotate about longitudinal axis A-A. While drive tube 117 rotates, italso translates between proximal and distal positions. A proximal end124 a of a firing rod 124 is attached to a distal end 117 b of drivetube 117. Consequently, moving drive tube 117 longitudinally causes thelongitudinal translation of firing rod 124. A portion of firing rod 124is positioned within housing 118. Another portion of firing rod 124extends through movable portion 120 and elongate portion 130. A distalend 124 b of firing rod 124 b is configured to be operatively connectedto tool assembly 140. When tool assembly 140 is mounted to elongateportion 130, a longitudinal translation of firing rod 124 causes theactuation of end effector 144.

Housing 118 further contains a first board 202 that is part of atransmission system. The transmission system is adapted to transmitelectrical power, control signals, feedback, sensing signal, or anycombination thereof between first board 202 and a second board 204disposed in movable portion 120. In one embodiment, the electrical powertransmitted by transmission system stems from power source 119 (see FIG.3). Control signals, feedback, sensing signals transferred by thetransmission system originate from sensors, control systems, andfeedback systems placed throughout surgical instrument 100.

Surgical instrument 100 includes sensors, control systems, and/orfeedback systems located inside or outside handle assembly 110, movableportion 120, elongate portion 130 and/or tool assembly 140. Certainsensors, for instance, determine the operational stage of surgicalinstrument 100. Specifically, these sensors detect, among other things,articulation, rotation, clamping, and firing of end effector 144 or anyother component of surgical instrument 100. Different types of sensorsmay be used in different ways to determine the operation stage ofsurgical instrument 100. For example, limit switches, proximity sensors,potentiometers, linear variable displacement transducer (LVDT), and/orshaft encoders may be employed to control and/or record the location offiring rod 124. Any of these sensors may also be used to detect aproperly loaded staple cartridge. Moreover, electrical contacts,proximity sensors, optical sensors, RF sensors, magnetic sensors, photodiodes, and mechanical or metallic sensors may be used to control and/orrecord information concerning end effector 144. Furthermore, othersensors may monitor surgical instrument 100 to minimize the risk ofoverloading. For instance, thermal sensors, thermistors, thermopiles,thermo-couples, and thermal infrared imaging systems may monitor thetemperature of first motor 115 or any other component of surgicalinstrument 100. In some embodiments, surgical instrument 100 includes anidentification sensor for identifying the type of loading unit and/orstaple cartridge loaded on surgical instrument 100. These identificationsensors may include infrared, cellular chips, radiofrequencyidentification chips, microchips, emitters and transmitters located intool assembly 140. These identification sensors communicate with firstor second board 202, 204 or a receiver disposed therein. Some sensorstransmit an electrical signal, whereas other sensors employ other meanssuch as optics, lights, RF and magnets.

In addition to the sensors, some embodiments of surgical instrument 100include systems, means, or devices for providing feedback to the user.For instance, display screens may be integral or separate from surgicalinstrument 100 for aiding the control of instrument 100. These displayscreens provide the user with useful information about operationalcharacteristics of surgical instrument 100. Besides display screens,other feedback systems may be incorporated into surgical instrument 100.Some embodiments of surgical instrument 100 have pulsed patterns oflights, acoustic feedback (such as buzzers, bells or beeps sounded atselected time intervals), verbal feedback, and/or haptic vibratoryfeedback (such as asynchronous motor or solenoids). In certainembodiments, the visual, auditory or haptic feedback increases ordecreases in intensity in response to a specific event, occurrence, oroperational characteristic.

With reference to FIGS. 3-6, the transmission system, which includefirst and second boards 202, 204, serves as a conduit for controlsignals, feedback, sensing signals, and/or electrical power from thesensors, control systems, feedback systems, and/or power sourcesdescribed above. In one embodiment, wires, leads, conductive strips,dielectric films, capacitors, cables, flexible conductors, conductiverings 121, or any other electrically conductive apparatus electricallyinterconnect first and second boards 202, 204. In the embodimentdepicted in FIG. 4, movable portion 120 houses conductive rings 121electrically coupling first board 202 to second board 204. Eachconductive ring 121 has a pressure or cantilevered contacts 123 adaptedto transfer electrical power, sensing signals, control signals, orfeedback between first and second boards 202, 204. In use, cantileveredcontacts 123 move and electrically close the circuit between powersource 119 and second motor 126 when the user moves articulation knob122 or triggers articulation switch 116.

Aside from second board 204, movable portion 120 contains a portion offiring rod 124, a second motor 126, and an articulation mechanism 128for articulating end effector 144 with respect to longitudinal axis A-A.Articulation mechanism 128 is operatively coupled to second motor 126.Second motor 126 starts and/or stops when the user actuates articulationswitch 116. Articulation mechanism 128 is also operatively connected toarticulation knob 122. In operation, a user may articulate end effector144 manually by moving articulation knob 122 or electromechanically byactuating articulation switch 116. End effector 144 articulates relativeto longitudinal axis A-A upon actuation of articulation switch 116 ormovement of articulation knob 122. The articulation of end effector 144may be regulated or monitored with sensor or control systemstransmitting signals, feedback, or data through either first or secondboards 202, 204.

First and second boards 202, 204 include printed circuit boards, controlcircuits, electronic circuits, and/or inductive circuits. As seen inFIG. 4, second board 204 may be a printed circuit board. Second board204 specifically includes a primary control circuit, a secondary controlcircuit, and/or a daughterboard. If second board 204 includes a primarycontrol circuit, then first board 202 includes a secondary controlcircuit. Conversely, if first board 202 includes a primary controlcircuit, then second board 204 includes a secondary control circuit. Inan embodiment where second board 204 includes a daughterboard, firstboard 202 includes a motherboard. In other embodiments, second board 204constitutes a motherboard with a daughterboard mounted thereon. In thisembodiment, the first board 202 may be a system or circuitry adapted tosend electrical power, control signals, or feedback to second board 204.In certain embodiments, first board 202 communicates wirelessly withsecond board 204. Several means and systems may be used to transmitelectrical power, signals, or information wirelessly from one board (202or 204) to another.

As discussed above, second board 204 may include or function as adaughterboard in an embodiment of the present disclosure. In thisembodiment, the daughterboard includes hardware and/or software forsensing, controlling, or providing feedback to the user. The sensing,controlling, and feedback functions of second board 204 can be performedwhile movable portion 120 remains stationary or during rotation orarticulation of movable portion 120. Movable portion 120 can be rotated360 degrees about longitudinal axis A-A and first board 202 is stillable to communicate sensing signals, control signals, electrical power,and/or feedback to second board 204. In an embodiment, second board 204includes a digital control module (“DCM”) to control or monitor theoperation of first and/or second motor 115, 126. In one embodiment, theDCM of second board 204 employs pulse-width modulation methods tocontrol the output of first and/or second motors 115, 126. The secondboard 204 of this embodiment regulates the voltage or pulse-widthmodulates the voltage to adjust the electrical power and/or torqueoutput to minimize the occurrences of system damage or to optimizeelectrical energy usage. In addition, an electric braking circuit may beincorporated in the DCM of second board 204 for controlling first orsecond motors 115, 126. In the case where second board 204 controls theoperation of first motor 115, second board 204 relays a control orsensing signal to first board 202. In response to the control andsensing signals received from second board 204, first board 202regulates or controls first motor 115. It is envisioned that the DCM ofsecond board 204 may control or monitor other components of surgicalinstrument 100. Moreover, first board 202 may transfer electrical energyfrom power source 119 to second board 204. Alternatively, movableportion 120 may include another power source (supplementing orsubstituting power source 119) for supplying electrical power to secondboard 204. If surgical instrument 100 only has one power source locatedwithin movable portion 120, then second board 204 transmits electricalpower wirelessly to first board 202. In the case that surgicalinstrument 100 has power source 119 and a second power source (notshown) positioned within movable handle 120, second board 204 may bepartially or entirely powered by the second power source.

In another embodiment, first board 202 includes a primary controlcircuit and second board 204 contains a secondary control circuit. Inthe case where first board 202 includes a primary control circuit,second board 204 receives electrical power, control signals, feedback,and/or sensing signals from first board 202. Second board 204 thenemploys the electrical power, control signals, feedback, and/or sensingsignals received from first board 202 to control, monitor, and/or drivesecond motor 126 or any other component of surgical instrument 100.

In the embodiment where second board 204 includes the primary controlcircuit and first board 202 includes the secondary control circuit,second board 204 transmits electrical power, control signals, feedback,and/or sensing signals to first board 202. First board 202 then utilizesthe electrical power, control signals, feedback, and/or sensing signalsreceived from the second board 204 to control, monitor and/or drivefirst motor 115 or any other component of surgical instrument 100.

As discussed above, an embodiment of surgical instrument 100 includes apower source (not shown) inside movable portion 120. This power sourcemay substitute or supplement power source 119. If this power sourcesubstitutes power source 119, second board 204 transmits electricalpower to first board 202 through a wireless connection, wires,capacitive conductors, leads, conductive rings 121, or any other form ofelectrical connection, to supply electrical power to first motor 115. Inone embodiment, electrical power, control signals, sensing signals andfeedback are transferred between first and second boards 202, 204through inductive coupling. In this embodiment, each of first and secondboards 202, 204 has an inductive circuit collectively forming aninductive interface. This inductive interface is configured to transferelectrical energy wirelessly between first and second boards 202, 204.The wireless electrical energy transfer between first and second boards202, 204 may be used to power control circuits, send or receive signals,and/or drive motors 115, 126, solenoids, lasers, RF energy sources fortissue ablation or electro-cautery systems. Moreover, the wirelesselectrical energy transfer may be employed to charge power sources (suchas batteries and capacitors) located within movable portion 120. Inembodiments where electrical energy is transferred wirelessly betweenfirst and second boards 202, 204, surgical instrument 100 does notnecessarily need wires, cables, or contacts electrically connectingfirst and second boards 202, 204.

Data may also be transmitted between first and second boards 202, 204through other means. In one embodiment, first board 202 includes acommunication transmitter and second board 204 includes a receiver, orvice versa. The transmitter and receive may utilize any suitableprotocol, standard, or technology for wirelessly transferring data,including, but not limited to, BLUETOOTH®, ANT3™, KNX™, Z WAVE™, X10™,wireless USB, WiFi™, IRDA™, NANONET™, TINY OS™, ZIGBEE™, radio, UHF, andVHF. Wireless energy transfer between first and second boards 202, 204allows sensors utilizing light, optics, RF, magnetism, or other meansthat do employ electrical signals to be used within movable handle 120without the need of wires or contacts. Second board 204, which islocated inside movable portion 120, may include electronic circuits, orany other suitable device or system, to decipher the signals provided bythese sensors.

It will be understood that various modifications may be made to theembodiments of the presently disclosed surgical instruments. Therefore,the above description should not be construed as limiting, but merely asexemplifications of embodiments. Those skilled in the art will envisionother modifications within the scope and spirit of the presentdisclosure.

What is claimed is:
 1. A powered surgical apparatus for engaging tissue,comprising: a first portion; a second portion rotatable about alongitudinal axis defined by the powered surgical apparatus; and atransmission system configured to transfer at least one of a signal orelectrical power between the first and second portions, the transmissionsystem including a first electronic board positioned in the firstportion and a second electronic board positioned in the second portion,wherein the second electronic board is movable relative to the firstelectronic board while the first and second electronic boards areelectrically coupled.
 2. The powered surgical apparatus of claim 1,wherein the first portion has a first motor.
 3. The powered surgicalapparatus of claim 2, wherein the first electronic board controls thefirst motor in response to a control signal received from the secondelectronic board.
 4. The powered surgical apparatus of claim 1, furthercomprising a tool assembly operatively coupled to the second portion. 5.The powered surgical apparatus of claim 1, wherein the first portionincludes a handle assembly.
 6. The powered surgical apparatus of claim1, wherein the second portion includes a conductive ring electricallycoupling the first electronic board to the second electronic board. 7.The powered surgical apparatus of claim 6, wherein the conductive ringhas cantilevered contacts.
 8. The powered surgical apparatus of claim 1,wherein the first electronic board includes a motherboard and the secondelectronic board includes a daughterboard.
 9. The powered surgicalapparatus of claim 1, wherein the first electronic board includes aprimary control circuit and the second electronic board includes asecondary control circuit.
 10. The powered surgical apparatus of claim1, wherein the transmission system is configured to transmit controlsignals between the first and second electronic boards.
 11. The poweredsurgical apparatus of claim 1, wherein the transmission system isconfigured to transmit feedback signals between the first and secondelectronic boards.
 12. The powered surgical apparatus of claim 1,wherein the transmission system is configured to transmit electricalpower wirelessly between the first and second portions.
 13. A poweredsurgical apparatus for engaging tissue, comprising: a first portion; asecond portion operatively coupled to a distal portion of the firstportion, the second portion configured to rotate about a longitudinalaxis defined by the powered surgical apparatus; and a transmissionsystem including a first electronic board positioned in the firstportion and a second electronic board positioned in the second portion,the second electronic board including a primary control circuit and asecondary control circuit, wherein the second electronic board ismovable relative to the first electronic board while the transmissionsystem transmits control signals between the first and second electronicboards.
 14. The powered surgical apparatus of claim 13, wherein thesecond portion includes a conductive ring electrically coupling thefirst electronic board to the second electronic board.
 15. The poweredsurgical apparatus of claim 13, wherein the conductive ring hascantilevered contacts.
 16. The powered surgical apparatus of claim 13,wherein the first portion includes a first motor, wherein the firstelectronic board controls the first motor in response to a controlsignal received from the second electronic board.
 17. The poweredsurgical apparatus of claim 13, further comprising a tool assemblyoperatively coupled to the second portion.
 18. The powered surgicalapparatus of claim 13, wherein the first portion includes a handleassembly.